Vortech HP500 EFI Installation Instructions Manual Download Page 1

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P/N: 4MB020-010
©2003 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
06DEC02 V1.0(4MB HP500 v1.0)

MERCRUISER

MARINE

HP500

EFI

Supercharger System

Installation Instructions

1998 - 2002

Summary of Contents for HP500 EFI

Page 1: ...P N 4MB020 010 2003 Vortech Engineering LLC All Rights Reserved Intl Copr Secured 06DEC02 V1 0 4MB HP500 v1 0 MERCRUISER MARINEHP500EFI Supercharger System Installation Instructions 1998 2002...

Page 2: ...is instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer technician Please call Vortech Engineering for installers in your area FO...

Page 3: ...EPARATION REMOVAL 1 2 SUPERCHARGER OIL DRAIN 2 3 SUPERCHARGER OIL FEED 3 4 MOUNTING BRACKETS 4 5 FUEL INJECTOR REPLACEMENT 8 6 FUEL SYSTEM UPGRADE 10 7 COMPUTER AND MAP SENSOR SENSOR 12 8 THERMOSTAT R...

Page 4: ...rly set correct air to fuel ratios proper drive specifications and fuel systems This product is intended for use on healthy well maintained engines Installation on a worn out or damaged engine is not...

Page 5: ...supercharged use caution when making propeller selection Selecting a propeller which will allow the engine to con stantly bump against the engine speed limiter the Vortech supplied ECM is programmed f...

Page 6: ...over A F Marine S C Pol 1 4MA017 031 Standoff A F Marine 2 7A250 076 1 4 20 x 3 4 SHCS S S 2 7A250 105 1 4 20 x 1 Set Screw 2 7P250 124 1 4 NPT To 1 2 Barb 1 7P250 146 1 4 NPT Street Elbow 1 7R005 006...

Page 7: ...s 2 7A375 126 3 8 16 x 1 25 HXHD GR8 Plt 2 7A375 201 3 8 16 x 2 SHCS 2 7A375 226 3 8 16 x 2 1 4 SS HCS 1 7A375 277 3 8 16 x 2 75 SHCS Stnls 1 7A375 350 3 8 16 x 3 1 2 HXHD 1 7A375 450 3 8 16 x 4 1 2 S...

Page 9: ...ing to the back of the raw water pump Slide the raw water pump with the bracket still attached to it off of the engine I Remove the three 7 16 studs from the front starboard side of the engine J Remov...

Page 10: ...cover and thread into the fitting C Remove the engine s port side valve cover and cover the exposed valve train with a clean rag to keep debris out and prevent contamination Drill two 203 holesthroug...

Page 11: ...ttingsothatthehorizontal female port is pointed toward the transom C Thread a 1 8 NPT x 4 x 90 fitting into the open port on the TEE fitting D Attach the oil feed line to the previously installed 4 fi...

Page 12: ...eventa tive B Reattach the modified alternator bracket to the engine using the stock hardware Install a 3 8 16 x 3 4 HHCS with washer into the hole previously enlarged and tighten C Following the diag...

Page 13: ...4 MOUNTING BRACKETS Cont d Fig 4 d D To align the bracket properly thread the 7 16 14 x 4 1 2 socket head cap screw into the third threaded hole on the cylinder head Tighten the two 7 16 14 x 2 socke...

Page 15: ...to the power steering pump spacer plate and bolts Orient the pump so that the inlet is pointing to the port side Secure the pump with the stock nylock nuts and washers See Fig 4 d H Remove the engine...

Page 16: ...fuel rails to the lower intake manifold F Mark each of the injector connectors with mask ing tape and a pen corresponding to each cylin der port This will aid in reinstallation G Disconnect each one o...

Page 17: ...e attach the regulator to the fuel rail See Fig 5 f L Install the new injectors into the fuel rail first using a small amount of oil to lubricate the O rings Reinstall the injector retaining clips M I...

Page 18: ...uel line 5 8 and 4 6 female swivel fittings Measure the distances between each of thefuelsystemcomponentsandwritethelengths next to each fuel line on the diagram It is impor tant to maintain a fuel li...

Page 19: ...S SYSTEM MAY REQUIRE SOME MODIFICATION ADAPTER FITTING LOCATION DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 HOSE END 37 3 8 PIPE PLUG 3 8 NPT x 8 x 45 37 JIC 1 2 HOSE UNI...

Page 20: ...or to the upper intake manifold the MAP sensor is located on the top port side of the manifold Carefully remove the MAP sensor from the manifold D RemovetherubbergrommetfromthestockMAP sensor and inst...

Page 21: ...e brass TEE and running back to each exhaust manifold Reconnect the remaining water lines to the thermostat housing 8 THERMOSTAT REPLACEMENT EXHAUST MANIFOLD MODIFICATIONS Fig 8 c Fig 8 b Fig 8 a NOTE...

Page 22: ...d cap screw and 7 16 washer B Install the threaded nipple into the fuel water separator housing Install the housing and the cooler support bracket onto the previously in stalled 3 8 plate using 2 5 16...

Page 23: ...stainless steel TEE into the open end of the line Cut 5 1 4 off of the 8 piece of hose and install onto the TEE See Fig 10 b Install the fuel cooler into the open hose D Connect the fuel cooler to th...

Page 24: ...y from the engine B Using the three 3 8 16 x 4 3 4 HHCS and wash ers mount the crank pulley assembly to the balancer Use a small amount of thread locking compound on each of the screws Torque each of...

Page 25: ...r InstallthesuppliedT boltclamp onto the supercharger inlet duct and carefully slide the duct onto the supercharger inlet flange Use caution when sliding the duct onto the su percharger It is very imp...

Page 26: ...as shown See Fig 12 e H2 Engines without power steering pump Remove the 4 idler from the factory bracket Attach the support plate to the mounting plate and supercharger Three of the supplied 12mm was...

Page 27: ...MA010 094 7C012 051 4FD017 011 7A375 277 7J012 092 7C012 020 7B375 250 DESCRIPTION Automatic Belt Tensioner 3 8 Flat Washer 7 16 14 Nut 7 16 AN Washer 7 16 14 x 2 75 SHCS Idler 750 x 1 536 Spacer Idle...

Page 28: ...crank and supercharger pulleys Using a box end wrench on the tensioning wheel bolt pull the tensioner as far back as possible and carefully slip the belt over the crank pulley See Fig 12 g for belt r...

Page 29: ...2 3 4 HHCS and M12 x 25mm HHCS See Fig 12 j The stock steering bracket will have to be cut and welded to the oil filter bracket See Fig 12 k 12 SUPERCHARGER MOUNTING cont d Fig 12 j Fig 12 k Fig 12 i...

Page 30: ...ing the four supplied 5 16 18 x 3 4 socket head screws Use a thin coating of RTV sealer between the mating surfaces of the charge cooler housing and the discharge duct see Figs 13 a 13 b B Attach the...

Page 31: ...nto the bot tom of the chargecooler core H Slide the 4 x 2 sleeve and two 64 hose clamps onto the throttle body Insert discharge duct B into the sleeve and secure with the hose clamps I Slide one of t...

Page 32: ...equired C Re attach the vacuum hose to the fuel regulator Fuel rail pressure should drop slightly If fuel pressure does not drop ensure that the vacuum hose is not kinked D Water test the vessel with...

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